Lean NOx trap/conversion catalyst

ABSTRACT

A process and composition for converting nitrogen oxides present in exhaust gases produced by an internal combustion engine utilize cobalt and at least one alkali metal or alkaline earth metal as a component of an adsorbent. The process involves contacting the exhaust gas with an adsorbent which adsorbs the nitrogen oxides in lean-burn conditions and recurrently reducing the oxygen concentration of the exhaust gas. During such periods of reduced oxygen concentration, the nitrogen oxides are then desorbed and reduced to nitrogen, thereby reducing the concentration of the nitrogen oxides in the exhaust gas. The composition of the adsorbent comprises an oxide support and at least two components loaded on the support and containing cobalt and at least one alkali metal or alkaline earth metal. The composition demonstrates improved activity at higher temperatures and improved thermal stability.

FIELD OF THE INVENTION

The present invention relates to improvements in emission control for partial lean-burn vehicle engines. In particular, the present invention is directed to the emission control of nitrogen oxides from exhaust gas of internal combustion engines, including diesel engines.

BACKGROUND OF THE INVENTION

Exhaust gases from vehicle engines primarily contain carbon oxides (CO and CO₂), nitrogen oxides (NO_(x)), hydrocarbons, sulfur dioxide, and soot. At present, one of the most significant problems is removal of nitrogen oxides, NO_(x), which are produced during high temperature combustion. In the case of “lean-burn” or partial lean-burn engines, in which there is an excess of oxygen in the exhaust gases, the reduction of NO_(x) to N₂ is particularly difficult because reducing components in the exhaust are often completely consumed by the oxygen that is present in large excess.

Catalysts are employed in the exhaust systems of automotive vehicles to convert CO, CO₂, hydrocarbons, and NO_(x), produced during engine operation into more desirable gases. When the engine is operated in a stoichiometric air/fuel ratio, catalysts containing palladium, platinum or rhodium, also known as “three way catalysts,” are able to efficiently convert all the gases simultaneously. However, when the engine is operated in “lean-burn” conditions, to realize a benefit in fuel economy, such three way catalysts are able to convert CO and hydrocarbons, but are not efficient in the reduction of NO_(x).

Previous attempts to develop a Lean NO_(x) Catalyst (LNC) that will selectively catalyze NO_(x) reduction by HC's has met with limited success. Catalyst materials developed to date that catalyze the HC—NO_(x) reaction allow only about 30 to 50% NO_(x) conversion under conditions of interest. These catalysts are usually either platinum (Pt) group metals (PGM) containing materials that function only at low temperatures (150-200° C.) or base metal materials that function at higher temperatures (300-600° C.). The LNC approach on its own, however, is not sufficient to achieve acceptable NO_(x) reduction to allow future legislated limits to be achieved.

Certain or alkali earth metals such as potassium or strontium in combination with platinum are capable of storing or adsorbing nitrogen oxides under lean conditions, or in conditions of excess oxygen. More specifically, the platinum first oxidizes NO to NO₂ and the NO₂ subsequently forms a nitrate complex with the alkali or alkaline earth material. For simplicity herein, this sequence of reactions and adsorption shall be referred to as nitrogen oxides being adsorbed, even though NO is not adsorbed but is actually first converted to NO₂ which is then adsorbed. In a rich environment caused, for example, by a regeneration pulse, the nitrate is thermodynamically unstable and the stored NO_(x) is released. The NO_(x) then, with the aid of a catalyst, reacts with reducing species in the exhaust gas to form N₂. These adsorbents are known as Lean NO_(x) Trap catalysts (LNT).

Some shortcomings have been identified for the LNT approach. First, a limited operating temperature window exists for the LNT. As with three-way catalysts, a minimum temperature is required for NO_(x) adsorption and conversion. However, unlike the three-way catalysts, NO_(x) adsorption and conversion decreases with increasing temperature above a certain temperature (usually about 350 to 400° C.), due to decreasing stability of the adsorbed nitrate. A second shortcoming of the LNT is the high cost due to the use of platinum group metals.

There remains a need for improved NO_(x) conversion catalysts for automotive lean-burn operation emissions.

SUMMARY OF THE INVENTION

The present invention pertains to a process and composition which converts nitrogen oxides present in exhaust gas produced by an internal combustion engine. The composition of an adsorbent of the present invention comprises an oxide support and at least two components loaded on the oxide support and containing cobalt and at least one alkali metal or alkaline earth metal. The most preferred alkali metal is potassium, however other alkali metals may be used, such as cesium. The components may include additional constituents, such as platinum group metals, but in some cases may be used without any additional constituents. The process comprises the steps of contacting the exhaust gas containing nitrogen oxides with an adsorbent of the present invention, where the adsorbent adsorbs the nitrogen oxides in lean-burn conditions, and then recurrently reducing the oxygen concentration of the exhaust gas. The reduction in oxygen concentration is done in a manner to cause desorption of the nitrogen oxides and reduction of the nitrogen oxides in the exhaust gas to nitrogen.

In a preferred embodiment of the present invention, the process also includes contacting the exhaust gases with a catalyst such as a platinum group metal, before or while contacting the exhaust gases with the adsorbent. This step may be performed in order to increase the conversion of the nitrogen oxides in the exhaust gas. The selected catalyst or the platinum group metal may be deposited on the oxide support with the adsorbent, but is preferably disposed on the upstream side of the oxide support.

The present invention is also directed to an exhaust system for converting nitrogen oxides present in exhaust gas provided by an engine. The system includes an upstream catalyst and a downstream catalyst. The upstream catalyst may be a three way catalyst, a lean NO_(x) catalyst, or an oxidation catalyst. The downstream catalyst is a lean NO_(x) trap of the present invention.

It is understood that both the foregoing general description and the following detailed description are exemplary, but not restrictive, of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The FIGURE is a graph showing nitrogen oxide conversion of the cobalt-potassium trap (also referred to herein as an “adsorbent”) along with comparative examples.

DETAILED DESCRIPTION OF THE INVENTION

The present invention pertains to a process and composition which converts nitrogen oxides present in exhaust gas produced by an internal combustion engine. The phrase converting nitrogen oxides means that at least some, and preferably almost all, of the nitrogen oxides entering the catalyst are converted to nitrogen. The present invention is also directed to an internal combustion engine exhaust gas catalyst system comprising a nitrogen oxide trap (LNT) (also referred to herein as an “adsorbent”), and the process of converting NO_(x) in exhaust gases from the engine.

The process for converting nitrogen oxides present in exhaust gases produced by an internal combustion engine first comprises the step of contacting the exhaust gas containing nitrogen oxides with an adsorbent of the present invention capable of adsorbing the nitrogen oxides in lean-burn conditions. The lean burn conditions involve an excess of oxygen, which is typical in exhaust gases. The adsorbent then stores the NO_(x) during the conditions of excess oxygen. When the exhaust flowing into the LNT is lean (i.e. high oxygen content), NO in the exhaust is catalytically oxydized to NO₂ and then stored by the adsorbent as a nitrate salt.

The second step of the present process comprises recurrently reducing the oxygen concentration of the exhaust gas in a manner to cause desorption of the nitrogen oxides and reduction of the nitrogen oxides in the exhaust gas to nitrogen. Reducing the oxygen concentration in the exhaust gas produces a “rich” environment. Such a rich environment may be achieved by providing a regeneration pulse, which is a sharp decrease in the air-to-fuel ratio for a short period of time. The term “recurrent” as used herein is meant to encompass both reductions in the oxygen concentration at regular intervals and reductions at random intervals. The manner of effecting the decrease in oxygen concentration and the extent of the decrease is well-known in the art.

The stored nitrates during the rich, or oxygen deficient, environment are thermodynamically unstable, and thus are released by the adsorbent. The cobalt of the adsorbent also acts as a catalyst to catalyze a reaction between the NO_(x) and the reducing species present in the exhaust gas, to produce N₂. Such a rich air-fuel ratio is used periodically as a regeneration pulse to assist in the regeneration of the LNT adsorbent. In the oxygen deficient environment present during the regeneration pulse, NO_(x) compounds released from the adsorbent are catalytically reduced to N₂ upon contact with the catalyst in the presence of carbon monoxide and residual hydrocarbons in the exhaust gas.

The adsorbent of the present invention comprises cobalt (Co) and an alkali metal or alkaline earth metal, preferably potassium (K), and is loaded on an oxide support. The adsorbent of the present invention may be in the form of an LNT. As is well known, the metals referred to herein actually exist within the adsorbent or other catalysts as oxides. In addition, it is believed that an adsorbent of the present invention including cobalt and potassium form simple oxides, as opposed to compound oxides. The phrase “loaded on” is used to cover all manners in which a catalytically or adsorpively active component (e.g., cobalt or potassium) can be associated with an oxide, such as by being carried on the oxide or ion-exchanged onto the oxide.

Any known high surface area oxide support may be used, and the specifics of the support do not appear to be critical for the present invention. Both natural and synthetic zeolites as well as acidic, basic or neutral zeolites may be used as catalyst support material. Further, the support material may also comprise metal oxides such as, but not limited to, zirconium oxide (ZrO₂) and aluminum oxide (Al₂O₃). Other supports such as silica, titania, etc. may also be used. Preferred embodiments of the present invention incorporate ceria, or CeO₂, as the oxide support.

A preferred LNT for the present invention comprises cobalt and potassium on a ceria support. The Co/alkali and/or alkaline earth metal mixture may be binary or ternary. Binary mixtures include Co/K, Co/Cs, and Co/Ba. Examples of ternary mixtures include Co/K/Cs, Co/K/Ba, and Co/Cs/Ba. The relative amounts or the metals in the components will depend on a number of factors including the metals used, the exhaust environment, and the desired properties of the adsorbent. In many cases, the binary metal oxide particles of Co/alkali metal may contain Co and an alkali metal in mole ratios of between 5:1 to 1:5. More preferably, the binary ratio is between 2:1 to 1:2.

The LNT of the present invention may additionally include one or more platinum group metals (PGMs) as part of the catalyst system, in addition to the cobalt and the alkali and/or alkaline earth metal group. Platinum group metals include platinum, palladium and rhodium or a combination thereof. The amount of PGM to be used is well known in the art, however, a preferred weight percentage range would be from 0.01% to 5.0% of the total support material. In the present application, a PGM is not necessary for conversion of the NO_(x) to N₂; however, it may be advantageous in some cases. For example, a PGM may be employed to increase low temperature activity or for higher thermal stability. The LNT of the present invention, however, does not require the use of a PGM for the conversion of NO_(x). Cobalt serves as an effective catalyst for the reaction to take place between the nitrates and the reducing species in the exhaust gas to form nitrogen gas.

The present LNT composition can be used additionally with an upstream catalyst in an exhaust system, where the LNT of the present invention is placed downstream from such catalysts. The upstream catalyst aids in achieving a greater reduction of nitrogen oxides, at least during periods of oxygen reduction. Conventionally known three-way catalysts (TWC), lean NO_(x) catalysts (LNC), or oxidation catalysts may be used for this purpose. As is well known, these upstream catalysts may perform other functions, such as HC or CO reduction.

The composition of the present invention can be made and used in a manner consistent with conventional LNTs. The cobalt and alkali or alkaline earth metal components may be applied to a substrate or washcoat, which are known in the art, as described in the following examples. The catalysts of the present invention, including Co/K are deposited on the support material, either simultaneously or sequentially. As seen generally from examples which follow, the composition can be made by mixing Co or a salt thereof with K or a salt thereof, dissolving the mixture in water, then loading it onto an oxide support such as CeO₂. The resulting powder is then dried at temperatures ranging from 60° C. to 150° C., although preferably at 120° C. for 12 hours. The dried powder is then calcined at temperatures ranging from 400° C. to 600° C., preferably at 500° C. for 4 hours.

As will be described by the test procedure and examples which follow, Co with preferably K or other alkali and/or alkaline earth metals results in higher NO_(x) conversion, even at high temperatures such as 350° C. to 500° C. Thus, an improved LNT catalyst is described by the present invention. The operating temperature depends on the adsorbent used.

EXAMPLES

A nitrogen oxide trap according to an embodiment of the present invention was prepared as follows. In a slurry impregnation method, a solution of 4.6 g of Co(NO₃)₂.6H₂O and 1.6 g of KNO₃ in 20 ml of water was added to a suspension of 10 g of CeO₂ in 50 ml of water. The mixture was evaporated while being vigorously stirred until achieving a paste, which was dried in an oven for 24 hours at 120° C. The resulting powder was calcined at 500° C. for 4 hours, then aged at 850° C. for 24 hours in air.

The samples were tested in a laboratory powder reactor with a procedure that consisted of a precondition followed by a lean-rich cycled test. 0.1 g of material was loaded in the reactor and the sample was exposed to a constant total gas flow rate of 200 standard cm³/min.

The sample was preconditioned on ramp to 650° C., held for 15 minutes, cooled to 400° C., all under the rich conditions listed Table 1. The temperature was held at 400° C. and the cycle of 60 sec. lean/5 sec. rich for 20 cycles. Then the sample was cooled to 150° C. while cycling 30 sec. lean/10 sec. rich.

After preconditioning, the LNT activity was measured at 150° C. by exposing the sample to 10 cycles at 120 sec. lean/5 sec. rich and calculating NO_(x) conversions for each of the last 3 cycles. The conversions for the 3 cycles were then averaged and reported as shown in FIG. 1. The LNT activity measurement was then repeated at 150, 225, 350, 450, and 500° C.

TABLE 1 Gas Compositions GAS RICH LEAN NO 500 ppm 500 ppm CO₂  10% 10% O₂ — 12% CO 7.5% — H₂ 2.5% —

As seen from FIG. 1, the Co/K sample prepared by slurry impregnation method was compared with Mn/K supported on CeO₂ and Pt/K supported on Al₂O₃. The Co/K LNT showed significantly higher percentage conversion of the NO_(x) at higher temperatures than the Mn/K and Pt/K. The following Table 2 compares the results of the Test procedure:

TABLE 2 NO_(x) Conversion of 850° C. Aged Samples at SV = 25K with 120 sec. lean/5 sec. rich 350° C. 450° C. 500° C.  9% Co/6% K 69% 80% 78% 10% Mn/10% K 12% 33% 30%  1% Pt/6% K 32% 45% 37%

The present catalyst system shows higher LNT NO_(x) conversion activity in middle to high temperature ranges (i.e. 350-500° C.) compared to previous adsorbent materials such as Ba, K, Cs, or Mn/K. Additionally, the Co/K material does not require a platinum group metal to convert NO to NO₂ for storage. The metal oxide-supported Mn/K system shows similar characteristics. As seen from FIG. 1, however, the Co/K system is more active and has a higher thermal durability than the Mn/K system. After aging at 850° C. for 24 hours in air, the Co/K system showed substantially better LNT activity than the Mn/K system.

The following supplemental examples are representative, not limiting of the invention.

Example 1

In an incipient wetness impregnation method may also be used, 4.6 g of Co(NO₃)₂.6H₂O and 1.6 g of KNO₃ (or 1.6 g of KOAc) were dissolved in 2.5 ml of water. 10 g of CeO₂ was impregnated with the above solution via sequential or co-impregnation. The resulting powder was dried in an oven for 24 hours at 120° C., calcined at 500° C. for 4 hours, then aged at 850° C. for 24 hours in air.

The NO_(x) conversion of Co/K supported on CeO₂ showed similar activities at the same composition, regardless of the preparation method.

Example 2

A solution of 9.8 g of Co(NO₃)₂.6H₂O and 3.4 g of KNO₃ in 20 ml of water was added to a suspension of 20 g of CeO₂ in 50 ml of water. The mixture was evaporated while being vigorously stirred until achieving a paste, which was dried in an oven for 24 h at 120° C. It was calcined at 500° C. for 4 hours and aged at 850° C. for 24 hours in air.

NO_(x) conversion (%) at 120 s lean/5 s rich cycles: 76% at 350° C., 81% at 450° C. and 75% at 500° C.

Example 3

3.11 g of Co(NO₃)₂.6H₂O was dissolved in 2.3 ml of water, and then impregnated onto 10 g of CeO₂. The powder was dried in an oven for 24 hours at 120° C. and calcined at 500° C. for 4 hours. A 1.6 g of KNO₃ was dissolved in 3.5 ml of water, and then impregnated onto the Co/CeO₂. The resulting powder was dried in an oven for 24 hours at 120° C. The sample was calcined at 500° C. for 4 hours and aged at 850° C. for 24 hours in air.

NO_(x) conversion (%) at 120 s lean/5 s rich cycles: 79% at 350° C., 84% at 450° C. and 76% at 500° C.

Example 4

4.69 g of Co(NO₃)₂.6H₂O was dissolved in 2.0 ml of water, and then impregnated onto 10 g of CeO₂. The powder was dried in an oven for 24 hours at 120° C. then calcined at 500° C. for 4 hours. 1.1 g of KNO₃ was dissolved in 3.5 ml of water, and then impregnated onto the Co/CeO₂. The resulting powder was dried in an oven for 24 hours at 120° C., calcined at 500° C. for 4 hours, and aged at 850° C. for 24 hours in air.

NO_(x) conversion (%) at 120 s lean/5 s rich cycles: 75% at 350° C., 82% at 450° C. and 76% at 500° C.

Example 5

3.11g of Co(NO₃)₂.6H₂O was dissolved in 2.3 ml of water, and then impregnated onto 10 g of CeO₂. The powder was dried in an oven for 24 hours at 120° C. and calcined at 500° C. for 4 hours. 1.1 g of KNO₃ was dissolved in 3.5 ml of water, and then impregnated onto Co/CeO₂. The resulting powder was dried in an oven for 24 hours at 120° C., calcined at 500° C. for 4 hours and aged at 850° C. for 24 hours in air.

NO_(x) conversion (%) at 120 s lean/5 s rich cycles: 81% at 350° C., 85% at 450° C. and 79% at 500° C.

Example 6

A solution of 7.0 g of Co(NO₃)₂.6H₂O and 6.0 g of Ba(NO₃)₂ in 65 ml of water was added to a suspension of 20 g of CeO₂ in 50 ml of water. The mixture was evaporated while being vigorously stirred until achieving a paste, which was dried in an oven for 24 hours at 120° C. The sample was then calcined at 500° C. for 4 hours and aged at 850° C. for 24 hours in air.

NO_(x) conversion (%) at 120 s lean/5 s rich cycles: 20% at 350° C., 15% at 450° C. and 14% at 500° C.

Example 7

A 1.38 g of Co(NO₃)₂.6H₂O and 1.4 ml of Cs solution (436 g Cs/L) was dissolved in 3.5 ml of water, and then impregnated onto 10 g of CeO₂. The powder was dried in an oven for 24 hours at 120° C., calcined at 500° C. for 4 hours, then aged at 850° C. for 24 hours in air.

NO_(x) conversion (%) at 120 s lean/5 s rich cycles: 25% at 350° C., 19% at 450° C. and 18% at 500° C.

Example 8

A solution of 3.1 g of Co(NO₃)₂.6H₂O, 1.1 g of KNO₃ and 3.3 ml of Cs solution (436 g Cs/L) in 20 ml of water was added to a suspension of 20 g of CeO₂ in 50 ml of water. The mixture was evaporated while being vigorously stirred until achieving a paste, which was dried in an oven for 24 hours at 120° C., calcined at 500° C. for 4 hours, then aged at 850° C. for 24 hours in air.

NO_(x) conversion (%) at 120 s lean/5 s rich cycles: 25% at 350° C., 48% at 450° C. and 46% at 500° C.

Example 1 was similar to the test procedure (uses same amount of Co/K), except an impregnation method was used. Examples 2-5 used different ratios of Co and K as the washcoat. Example 6 used the binary mixture of Co and Ba. Example 7 used Co and Cs. Example 8 used the ternary mixture of Co/K and Cs. Resulting NO_(x) conversion of each example at varying temperatures is listed in Table 3.

TABLE 3 NO_(x) conversion at 120 sec. lean/5 sec. rich cycles LNT 350° C. 450° C. 500° C. Test Co/K on 69% 80% 78% Procedure CeO₂ Example 1 Co/K on 69% 80% 78% CeO₂ Example 2 Co/K on 76% 81% 75% CeO₂ Example 3 K on Co/CeO₂ 79% 84% 76% Example 4 K on Co/CeO₂ 75% 82% 76% Example 5 K on Co/CeO₂ 81% 85% 79% Example 6 Co/Ba on 20% 15% 14% CeO₂ Example 7 Co/Cs on 25% 19% 18% CeO₂ Example 8 Co/K/Cs on 25% 48% 46% CeO₂

The results of the Examples for the present invention show a relatively high NO_(x) conversion at the temperature range from 350° C. to 500° C. Example 6-example 8 have used Ba or Cs and have shown lower NO_(x) conversion than the previous use of K. As stated before, although other alkali metals are contemplated for use with the present LNT, the preferred alkali metal is K. These examples are merely representative of the present invention and are not limiting in any way.

Although illustrated and described herein with reference to certain specific embodiments and examples, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. 

What is claimed is:
 1. A composition which adsorbs nitrogen oxide present in exhaust gases produced by an engine during lean-burn conditions, said composition comprising: an oxide support; and a binary mixture of cobalt and potassium loaded on said support.
 2. The composition of claim 1, wherein said cobalt and said potassium are present in a mole ratio of between 5:1 to 1:5.
 3. The composition of claim 1, wherein said cobalt and said potassium are present in a mole ratio of between 2:1 to 1:2.
 4. The composition of claim 1, wherein said oxide support comprises ceria.
 5. The composition of claim 1, wherein said oxide support consists of ceria.
 6. The composition of claim 1, wherein the cobalt exists as cobalt oxide and the potassium exists as potassium oxide.
 7. The composition of claim 6, wherein the cobalt oxide and the potassium oxide are in the form of simple oxides. 